Connector mechanism for a sensor

ABSTRACT

A connector mechanism for safely and quickly attaching or detaching a sensor. The connector mechanism includes a sensor head assembly comprising a detector body with an internal channel, an open distal end, and a sensor head attachment connector (HAC) located within the channel. The HAC includes a first electrical connection having at least a first contact member and a first key component located in a fixed location relative to the first contact member. The connector mechanism includes a sensor cartridge comprising a cartridge housing with a probe component, a second electrical connection having at least a second contact member configured to mate with the first contact member, and a second key component that is located in a fixed location relative to the second contact member. The first and second key components engage one another before the first and second contact members engage one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of co-pending U.S. patent applicationSer. No. 14/843,235, filed Sep. 2, 2015, which is a Continuation ofInternational Patent Application No. PCT/US2014/024004, filed Mar. 12,2014, which claims priority to and the benefit of the filing date ofU.S. Provisional Application No. 61/781,333, filed on Mar. 14, 2013, allof which are incorporated herein by reference in their entirety.

BACKGROUND

The subject matter described herein relates generally to sensors, andparticularly to attaching and detaching a sensor cartridge from a sensorhead assembly.

Environmental sensing systems may include a variety of sensors fordetecting the presence and/or concentration of various chemicals inhazardous environments. For example, sensors may be used in hazardousenvironments for detecting the presence and/or concentration ofhazardous (e.g., combustible) and/or toxic gases.

The sensing systems generally include a sensor housed in a cartridge anda head assembly coupled to a mounting structure. The head assemblyprovides a removable electrical interface between a sensor and themounting structure. The sensor generally includes an interface having apin array to removably couple to the head assembly. However, theinterface requires manual alignment of the pin array such that thesensor cartridge cannot be mated to the head assembly in a blind fashion(e.g., an operator has to visual inspect and ascertain the orientationof the pin array to align the sensor to the head assembly). Furthermore,because the pin array is not guarded, pins may be damaged as theoperator attempts to properly align the pin array.

SUMMARY

The subject matter described herein relates to a connector mechanism forsafely and quickly attaching or detaching a sensor. The connectormechanism includes a sensor head assembly comprising a detector bodywith an internal channel and an open distal end. The connector mechanismalso includes a sensor head attachment connector (sensor HAC) locatedwithin the channel. The HAC may be oriented to face the distal end andrecessed within the channel remote from the distal end. The HAC mayinclude a first electrical connection having at least a first contactmember. The HAC may include a first key component that is located in afixed location relative to the first contact member. The connectormechanism also includes a sensor cartridge comprising a cartridgehousing that includes a probe component. The sensor cartridge may beconfigured to be at least partially inserted through the open distal endinto the internal channel of the detector body. The sensor cartridge mayalso include a second electrical connection having at least a secondcontact member configured to mate with the first contact member. Thesensor cartridge may also include a second key component that is locatedin a fixed location relative to the second contact member. The first andsecond key components engage one another before the first and secondcontact members engage one another.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings, in which like numerals represent similar parts, illustrategenerally, by way of example, but not by way of limitation, variousembodiments discussed in the present document.

FIG. 1 is an illustration of the insertion of a sensor connector intothe sensor head channel for attaching the sensor to the sensor head.

FIG. 2 is an expanded representation of the sensor head assembly withthe sensor and retaining cap.

FIG. 3 is a perspective view of an embodiment of a sensor assembly.

FIG. 4 is an exploded perspective view of an embodiment of a sensor ofthe sensor assembly shown in FIG. 3.

FIG. 5 is a perspective view of an embodiment of a sensor head assemblyof the sensor shown in FIG. 4.

FIG. 6 is a perspective view of an embodiment of a sensor cartridge ofthe sensor shown in FIG. 4.

FIG. 7 is a cross-sectional view of an embodiment of a sensor headattachment connector and the sensor probe shown in FIG. 4.

FIG. 8 is a cut-away perspective view of the sensor shown in FIG. 4 witha cut-away portion showing the head attachment connector of FIG. 7.

FIG. 9 is a cut-away perspective view of the sensor shown FIG. 4 with acut-away portion showing the head attachment connector of FIG. 7 abuttedwith the sensor cartridge of FIG. 6.

FIG. 10 is a cut-away perspective view of the sensor shown in FIG. 4with a cut-away portion showing the head attachment connector of FIG. 7abutted and aligned with the sensor cartridge of FIG. 6.

DETAILED DESCRIPTION

As seen in FIGS. 1 and 2, a connector mechanism 10 for safely andquickly attaching or detaching a sensor or sensor assembly 40 to asensor head assembly 60. The sensor head assembly 60 has a sensorretaining cap 62 with an opening 66 which exposes the sensor to theatmosphere. The sensor retaining cap cavity 64 is equipped with twobayonet pins 70 for quarter turn sensor head accessories such as but notlimited to calibration adapter, water deluge guard, and positive flowthru adapter. A sensor head attachment connector 30 resides within thesensor head channel 68 and is accessible when the sensor retaining capis removed from the sensor head assembly 46.

As further seen in the figures, the sensor head attachment connector 30has a first electrical connection 32 that contains at least oneelectrical connection 32, preferably multiple electrical connections 32,e.g., 2, 3 4, 5, 6, 7, 8, 9 or any other number of electricalconnections 32 as desired. A first key component 90 is also part of thesensor head attachment connector 30, with the first key component 90 inthe fixed location relative to the first electrical connection 32. Assuch, the first electrical connection 32 remains in a permanent positionrelative to the first key component 90 regardless of the movement of thefirst key component 90. Additionally, the first electrical connection 32is recessed relative to the first key component 90, or stateddifferently, the first key component 90 is raised above the firstelectrical connection 32. Preferably the first key component 90 is acontinuous solid configuration, such as circular, oval rectangular,diamond, square, or other form, that permits, and is readily maneuveredto, insertions into or outside of a receiving shape. In one embodiment,the first key component 90 is inserted into a second key component 100or receiving shape. In another embodiment, the first key component 90that can be inserted into a receiving shape 100 has a solid interiorarea. The first electrical connection 32 may be located within and/oroutside of the first key component 90.

Referring again to the figures, the sensor component 40 includes asecond housing 42 having a probe component 50. Additionally, the sensor40 has a second electrical connection 44 configured to mate with thefirst electrical connection 32. The second key 100 is located on thesensor 40 and is in a fixed location relative to the second electricalconnection 44, with the second electrical connection 44 is recessedrelative to the second key component 100. As such, the second electricalconnection 44 remains in a permanent position relative to the second keycomponent 100 regardless of the orientation or movement of the secondkey component 100. Additionally, the second electrical connection 44 isrecessed relative to the second key component 100, or stateddifferently, the second key component 100 is raised above the secondelectrical connection 44. The second key component 100 is preferably acontinuous solid configuration, and configured in such a manner as tomate with the first key component 90 in such a manner as to be readilymaneuvered to, insertions into or outside of the first key component 90.In one embodiment, the second key component 100 is inserted into thefirst key component 90. In another embodiment, the second key component100 can be inserted into the first key component 90 and has a solidinterior area. The second electrical connection 44 may be located withinand/or outside of the second key component 100 as it is placed in aposition relative to the second key component 100 as to engage the firstelectrical connection 32 when the first 90 and second key components 100are mated. As such, the second key component 100 is configured tointerlock with the first key component 90, but the first 32 and second44 electrical connections are longitudinally blocked from engaging eachother until the first 90 and second 100 keys components are aligned.

As seen in FIG. 1, the connector mechanism 10 is particularly useful forhot swapping sensors in explosive environments.

In operation, referring to FIG. 2, the sensor probe component 50 fitswithin the sensor head cavity 68 for connection of the first 90 andsecond 100 keys components and first 32 and second 44 electricalconnections with such reduced angular movement from the longitudinalaxis of the channel 90 and probe 50 component that the first electricalconnection 32 does not contact any member of the sensor 40 and thesecond electrical connection 44 does not contact any member of thesensor head attachment connector 30 prior to the first 90 and second 100key components engaging each other. As the probe 50 is inserted into thesensor head channel 68, the first 90 and second 100 key components comeinto longitudinal contact with each other which prohibits furtherinsertion of the probe 50 into the sensor head channel 68. The probe 50is rotated or twisted in its longitudinally blocked position until thefirst key component 90 and second key component 100 are aligned. Oncethe first 90 and second 100 key components are aligned, the probe 50 canbe further inserted into the sensor head channel 68 such that the first90 and second 100 key components continue to engage each other. With thesensor 40 and sensor head assembly 60 aligned, as the first 90 andsecond 100 key component continue to engage, the first 32 and second 44electrical connections are aligned for insertion into one another. Oncethe first 90 and second 100 key components are fully engaged, thelongitudinal insertion of the probe 50 is blocked and the first 32 andsecond 44 electrical connections are now fully connected.

The subject matter described herein is particularly useful in sensorapplications where the sensor is guided in the detector head housing andthe connection is made in a blind, i.e., where the person inserting thesensor head do not have any visual indication of the proper line ofinsertion of the sensor head. The two surfaces of the plug and socket(the first and second key components) act like a bearing surfaceallowing the sensor to rotate until the sensor key and socket keywayalign sliding together allowing the electrical connection components,preferably eight (8) contacts, to mate. The subject matter describedherein is particularly useful in gas sensor and/or hot swappabledetector head designs.

FIG. 3 is a perspective view of an embodiment of a sensor assembly 110.The sensor assembly 110 includes a sensor 112 and a mounting structure114. As shown in FIG. 3, the sensor 112 is mounted to the mountingstructure 114 such that the sensor 112 is exposed within an environment116 for sensing one or more parameters within the environment 116. Thesensor 112 may be any type of sensor that is configured to sense anyparameter(s). For example, in some embodiments, the sensor 112 isconfigured to detect the presence and/or amount of a substance (e.g., avolatile gas and/or the like) within the environment 116. Examples ofother parameters that may be sensed by the sensor 112 include, but arenot limited to, pressure, density, temperature, relative humidity,and/or the like. The sensor 112 may be used in any application and theenvironment 116 may be any environment. In some embodiments, theenvironment 116 is a hazardous environment, such as, but not limited to,a petroleum well, a power plant, a petroleum pipe system, and/or thelike. For example, the sensor 112 may be used within a hazardousenvironment for detecting the presence and/or amount of a volatile gaswithin the hazardous environment.

The mounting structure 114 supports the sensor 112 such that the sensor112 is exposed within the environment 116 for performing sensingoperations. The mounting structure 114 may include any structure, means,configuration, and/or the like that enables the mounting structure 114to support the sensor 112 within the environment 116. In someembodiments, the mounting structure 114 is merely a panel and/or wall towhich the sensor 112 is mounted, while in other embodiments the mountingstructure 114 may include processing components, power supplycomponents, communications components, and/or the like that supportoperation of the sensor 112. For example, the mounting structure 114 mayhold one or more electrical power sources (not shown; e.g., a batteryand/or the like) and/or one or more electrical power distributioncomponents (not shown; e.g. electrical wires and/or cables, circuitboards, switches, relays, transformers, capacitors, voltage regulators,current regulators, and/or the like) for supplying electrical power tothe sensor 112 to power operation of the sensor 112. The mountingstructure 114 may hold one or more processing components (not shown;e.g., computers, processors, controllers, microprocessors, circuitboards, microcontrollers, memories, integrated circuits, and/or thelike) that process signals from the sensor 112 that represent theparameter(s) sensed by the sensor 112. Processing of signals from thesensor 112 optionally includes data logging operations. In addition oralternative to the power supply component(s) and/or the processingcomponent(s), the mounting structure 114 may hold one or morecommunication components (not shown; e.g., electrical wires and/orcables, circuit boards, other electrical pathways, switches, relays,communication nodes, and/or the like) that enables the sensor 112 tocommunicate with a remote location and/or other sensors. The remotelocation and/or the other sensors may contain one or more processingcomponents and/or electrical power components that relate to operationof the sensor 112.

Optionally, the mounting structure 114 may include an interior chamberthat is hermetically sealed to separate a volume of space within themounting structure 114 from the environment 116. For example, in theillustrated embodiment, the mounting structure 114 is anexplosion-resistant housing having an interior chamber 118 that holdsone or more processing components, power supply components, and/orcommunication components that relate to operation of the sensor 112. Theinterior chamber 118 is separated from the environment 116 such that anycombustion and/or explosion within the interior chamber 118 is lesslikely to extend into the environment 116. As such, any combustionand/or explosion that occurs within the interior chamber 118 is lesslikely to cause any substance within the environment to combust and/orexplode. The illustrated embodiment of the mounting structure 114 may becommonly referred to as an “explosion-proof transmitter enclosure.”Although described above as being an active sensor that requires asupply of electrical power to operate, the sensor 112 may be a passivesensor that does not require a supply of electrical power to operate.

FIG. 4 is an exploded perspective view of an embodiment of the sensor112 shown in FIG. 3. The sensor 112 includes a sensor head assembly 120,a sensor cartridge 122, and a retaining cap 124. The sensor 112 iselongated and extends along a central longitudinal axis 126. The sensorhead assembly 120 and the sensor cartridge 122 include a connectormechanism 128 for attaching and detaching the sensor cartridge 122 toand from the sensor head assembly 120. When the sensor cartridge 122 isattached to the sensor head assembly 120, the connector mechanism 128electrically connects the sensor cartridge 122 to the sensor headassembly 120. The connector mechanism 128 is discussed in further detailbelow. The sensor head assembly 120 is then electrically connected tothe mounting structure 114 via the wiring 182.

The sensor head assembly 120 includes a detector body 130. The detectorbody 130 extends a length along the central longitudinal axis 126 froman end 132 to an opposite end 134. The detector body 130 includes aninternal channel 136 that extends through the detector body 130 along atleast a portion of the length of the detector body 130. The internalchannel 136 extends into the detector body 130 through the end 134 suchthat the end 134 is open to the internal channel 136. The end 134 willbe referred to herein as an “open distal end” and as a “distal end.”

The connector mechanism 128 illustrated in FIG. 4 is shown positionedflush with the open distal end 134 for illustration purposes. Asdiscussed in further detail below, the connector mechanism 128 isrecessed into the detector body 130.

The sensor head assembly 120 may include an attachment member 138 formounting the sensor 112 to the mounting structure 114 (shown in FIG. 3).In the illustrated embodiment, the attachment member 138 includes athread 140 for threadably connecting the sensor 112 to the mountingstructure 114. But, in addition or alternatively to the thread 140, theattachment member 138 may use any other mounting strategy, such as, butnot limited to, an adhesive, an interference fit, a snap-fit, a latch, aclip, a clamp, a threaded fastener, and/or the like. In the illustratedembodiment, the attachment member 138 is located at the end 132 of thedetector body 130, however, the attachment member 138 may have any otherlocation along the detector body 130.

The sensor head assembly 120 may include an attachment member 142 formounting the retaining cap 124 to the detector body 130. The illustratedembodiment of the attachment member 142 includes a thread 144 thatenables the retaining cap 124 to be mounted to the detector body 130 bybeing threadably connected to the detector body 130. In addition oralternatively to the thread 144, the attachment member 142 may use anyother mounting strategy for mounting the retaining cap 124 to thedetector body 130, such as, but not limited to, an adhesive, aninterference fit, a snap-fit, a latch, a clip, a clamp, a threadedfastener, and/or the like. Although the attachment member 142 is shownas being formed at the end 134 of the detector body 130, the attachmentmember 142 may have any other location along the detector body 130. Thestructure and function of the retaining cap 124 will be discussed below.

The sensor cartridge 122 includes a cartridge housing 146 that extends alength along the central longitudinal axis 126 from an end 148 to anopposite end 150. The cartridge housing 146 includes an interior chamber152. The sensor cartridge 122 includes a sensing element (not shown)that is held within the interior chamber 152 of the cartridge housing146. The sensing element is configured to sense one or more parametersfrom the environment 116 (shown in FIG. 1). The sensing element may beany type of sensing element that is configured to sense the parameter(s)in any manner. In the illustrated embodiment, the sensing element is adiffusion type sensing element that senses the parameter(s) throughdiffusion. The cartridge housing 146 includes a diffusion opening 154that exposes the sensing element to the environment 116 to enable thesensing element to sense the parameter(s) through diffusion. Althoughshown as extending through the end 150 of the cartridge housing 146, thediffusion opening 154 may be positioned at any other location along thecartridge housing 146 that enables the sensing element to sense theparameter(s). Although only one is shown, the cartridge housing 146 mayinclude any number of diffusion openings 154. Any other type of sensingelement may be used in addition or in alternative to the diffusion typesensing element described herein.

As briefly discussed above, the sensor head assembly 120 and the sensorcartridge 122 include the connector mechanism 128. Specifically, thesensor head assembly 120 includes a sensor head attachment connector(sensor HAC) 156 of the connector mechanism 128 and the sensor cartridge122 includes a probe component 158 of the connector mechanism 128. Thesensor HAC 156 and the probe component 158 are configured to matetogether to electrically connect the sensor cartridge 122 to the sensorhead assembly 120. The sensor HAC 156 is located within the internalchannel 136 of the detector body 130. The cartridge housing 146 isconfigured to be at least partially inserted into the internal channel136 to mate the probe component 158 and the sensor HAC 156 to oneanother. As will be discussed below in more detail, the probe component158 includes a key component 160 that is configured to cooperate andinterlock with a key component 162 of the sensor HAC 156 to ensurecontact members 164 of the probe component 158 engage correspondingcontact members 166 of the sensor HAC 156 only when the key components162 and 160 are properly aligned with one another. The key component 160may be referred herein as a “second key component,” while the keycomponent 162 may be referred to as a “first key component.” Each of thecontact members 164 may be referred to herein as a “second contactmember,” and each of the contact members 166 may be referred to hereinas a “first contact member.”

The retaining cap 124 extends a length along the central longitudinalaxis 126 from an end 168 to an opposite end 170. The retaining cap 124includes an interior passage 172 that extends through the length of theretaining cap 124. The retaining cap 124 is configured to be mounted tothe detector body 130. When mounted to the detector body 130, theretaining cap 124 extends at least partially around the sensor cartridge122 for protecting the sensor cartridge 122 from damage (e.g., impactdamage). The sensing element of the sensor cartridge 122 is exposed tothe environment 116 through the internal passage 172, which is open tothe environment 116 at the end 170. The interior passage 172 optionallyincludes a screen (not shown) to facilitate preventing debris fromentering the interior passage 172 and possibly fouling the sensorelement.

The retaining cap 124 includes an attachment member 174 for mounting theretaining cap 124 to the detector body 130. In the illustratedembodiment, the attachment member 174 includes a thread (not shown) thatenables the retaining cap 124 to be mounted to the detector body 130 bythreadably connecting the retaining cap 124 to the thread 144 of thedetector body 130. Additionally or alternatively, the attachment member174 may use any other mounting strategy for mounting the retaining cap124 to the detector body 130, such as, but not limited to, an adhesive,an interference fit, a snap-fit, a latch, a clip, a clamp, a threadedfastener, and/or the like. Although the attachment member 174 is shownas being formed at the end of the retaining cap 124, the attachmentmember 174 may have any other location along the retaining cap 124.

Optionally, the retaining cap 124 includes an attachment member forconnecting an accessory (not shown) to the sensor 112. Examples ofaccessories include, but are not limited to, calibration adapters, waterdeluge guards, positive flow-through adapters, and/or the like. In theillustrated embodiment, the retaining cap 124 includes bayonet pins 176that connect to accessories using a bayonet-type connection. In additionor alternatively, any other type of connection may be used to connectaccessories to the sensor 112.

FIG. 5 is an end perspective view of an embodiment of the sensor headassembly 120 shown in FIG. 4. The sensor HAC 156 is located within theinternal channel 136. The sensor HAC 156 is recessed within the internalchannel 136 remote from the distal end 134 along the longitudinal axis126. In other words, the sensor HAC 156 is positioned within theinternal channel 136 a predetermined distance 184 from the distal end134. The distance from the distal end 134 and the position of the sensorHAC is referred to herein as the “staging” distance 184 and is discussedbelow. The sensor HAC 156 is oriented to face the open, distal 134 endof the sensor head assembly 120. Optionally, the sensor HAC 156 can bemounted to a printed circuit board (PCB) 180 or other electroniccomponents. The PCB 180 is then electrically connected to the wiring 182via the electrical contact member 202 that electrically connects thesensor 112 to processing components, power supply components,communication components, and/or the like that support operation of thesensor 112. In the illustrated embodiment, the sensor HAC 156 is shownas having a cylindrical shape, however, the sensor HAC 156 may includeany shape.

The sensor HAC 156 includes a first electrical connection 206 thatprovides an electrical connection between the wiring 182 and the sensorcartridge 122. The sensor HAC 156 also includes one or more firstcontact members 166 arranged circumferentially about a core area. Thefirst contact member 166 may be located in a fixed location relative tothe first key component 162. The first contact member 166 provides aconnection to conductively and electrically join the first electricalconnection 206 in the sensor HAC 156 to the second electrical 144connection in the sensor cartridge 122. Accordingly, the first contactmember 166 may join the second contact member 164 to the wiring 182. Thewiring 182 may then electrically join the sensor assembly 112 toprocessing and/or power components within the interior chamber 118 ofthe mounting structure 114. The first contact member 166 may include oneor more electrical connections (e.g., 1, 2, 3, 4, 5, 6, 7, or 8) asdesired. In the illustrated embodiment, the first contact member 166 isconfigured as a contact receptacle configured to receive the secondcontact member 164 that is pin shaped. Optionally, the first contactmember 166 and the second contact member 164 could be any compatibleshape to provide an electrical connection.

The sensor HAC 156 includes the first key component 162. The first keycomponent 162 is located in a fixed location relative to the firstcontact member 166. The first key component 162 is located on the sensorHAC 156 and the corresponding second key component 160 is located on thesensor probe component 158. Although shown as a standoff in theillustrated embodiment, the key components may be any set of compatiblemating features. For example, the first key component 162 may be aprotrusion oriented to extend toward the open distal end 134 and alignswith a recess or groove in the probe component 158. Alternatively thefirst key component 162 may be a continuous solid configuration, such ascircular, oval rectangular, diamond, square, trapezoidal, or other shapeconfigured to align and mate with the second key component 160 that maybe a negative image of the shape of the first key component 162.

Optionally, the sensor head assembly 120 may include additional keycomponents 186 within the internal channel 136. The additional keycomponents 186 may be a standoff extending radially inward within theinternal channel 136. In the illustrated embodiment, the additional keycomponents 186 are shown as standoffs extending radially inward towardthe central axis 126. However, the additional key components 186 may beany member that at least partially circumnavigates the internalperimeter of the internal channel 136. The additional key components 186may be positioned in a fixed location relative to the contact membersand are configured to engage with a second additional key component onthe probe component 158, as discussed below.

FIG. 6 is a perspective view of an embodiment of the sensor cartridge122 shown in FIG. 4 to better illustrate the probe component 158. Theprobe component 158 is configured to mate with the sensor HAC 156 andprovide an electrical connection between the sensor cartridge 122 andthe sensor head assembly 120 via the second electrical connection 204.Accordingly, the probe component 158 includes at least one of the secondcontact members 164 within the second electrical connection 204, whichis configured to mate with the corresponding first contact member 166 inthe first electrical connection 206. In the illustrated embodiment, thesecond contact member 164 is a pin and the first contact member 166 is areceptacle, however, any electrically mating member pair may be used.For example, the contact member 166 and 164 may be rectangular contactpads configured to abut against one another to form an electricalconnection between the contact pads.

The sensor probe component 158 includes a second key component 160. Thesecond key component 160 is located in a fixed location relative to thecontact member 164. As shown in the illustrated embodiment, the secondkey component 160 includes a groove 188 that receives the standoff 162.Also shown in the illustrated example, the probe component 158 includesan optional base key 190 that cooperates (e.g., sized and shaped toreceive) with the alternate key component 186 of the sensor HAC 156.

FIG. 7 is a cross-sectional view of a portion of the sensor HAC 156 andthe sensor probe component 158 aligned with one another, but spacedapart along the longitudinal axis 126 such that the sensor HAC 156 andthe probe component 158 have not mated (e.g. do not touch or abut oneanother). As discussed in detail below, the sensor cartridge 122 may berotated within the internal channel 118 about the longitudinal axis 126until the key component 162 aligns with the key component 160, toachieve the orientation illustrated. Additionally, the second keycomponent 160 is shown aligned with the first component 162, and thecontact member 164 is aligned with the contact member 166.

In the illustrated example, the contact member 166 is configured as areceptacle (e.g., a right circular cylindrical cavity). The contactmember 166 includes at least one spring-loaded contact elements 192situated along the internal perimeter of the contact member 166. Toelectrically couple the sensor cartridge 122 with the sensor HAC 120,the contact pin 164 may be inserted into the contact member 166 bymoving the sensor cartridge 122 along the longitudinal axis 126 towardthe sensor HAC 120. When inserted, the spring-loaded contact elements192 exerts a compressive force upon the contact member 166 providing afriction fit and electrical contact.

The second key component 160 may extend a key length 194 outward fromthe sensor probe component 158 along the longitudinal axis 126.Similarly, the contact member 164 may extend a contact length 196outward from the sensor probe component 158 along the longitudinal axis126. As shown, the key length 194 is greater than the contact length196. The key length 194 is greater than a contact length 196 to allowthe second key component 160 to contact a surface (e.g., the surface ofthe HAC) before the contact pin 164 can contact a surface. Accordingly,the second key component 160 engages the first key component 162 beforethe second contact member 164 engages the first contact member 166.

Optionally, the probe component 158 may include a shroud component 198.The shroud component 198 may be an extension of the probe component 158that is located a fixed location relative to the contact member 160. Theshroud component 198 may extend along the longitudinal axis 126 towardthe distal end of the sensor cartridge 122. Similar to the second keycomponent 160, the shroud component 198 may extend further toward thedistal end of the sensor cartridge 122 than the contact member 160. Inother words, the shroud component 160 may have a shroud length 200 thatis greater than the contact length 196. The shroud component 198 mayprotect the contact member 194 from damage (e.g., impact damage).

FIGS. 8, 9, and 10 illustrate the alignment and staging process wherethe contact members 164, 166 are aligned and joined.

FIG. 8 is a cut-away perspective view of the sensor cartridge 122received into the sensor head assembly 120 in an initial pre-loadedstage. In the pre-loaded stage, the sensor cartridge 122 is loaded(e.g., inserted or received) within the internal channel 136 and thesensor cartridge 122 is aligned with the sensor head assembly 120 alongthe longitudinal axis 126. The sensor HAC 120 is recessed by the stagingdistance 184 within the internal channel 136 from the open distal end134 of the head assembly 120. The staging distance 184 is apredetermined distance based on the dimensions (e.g., diameter, size,and/or shape) of the sensor cartridge 122 and/or the sensor headassembly 120 such that the sensor head assembly 120 limits angularmovement of the sensor cartridge 122 relative to the longitudinal axis126. In other words, the staging distance 184 is such that a portion ofthe sensor cartridge 122 resides within head assembly 120 such that thecartridge housing 146 is limited in movement to longitudinal androtational movement. Limiting angular movement of the sensor cartridge122 may encourage the contact member 164 to align with the contactmember 166. For example, as shown in the illustration, the contactmembers 164, 166 may require movement along the longitudinal axis 126 inorder to mate. As such, movement perpendicular to the longitudinal axis126 may cause the contact members 164, 166 to misalign and/or may damagethe contact members 164, 166.

Additionally, the sensor cartridge 122 has an outer diameter that fitsin close tolerance within an inner diameter of the distal end 134 of thesensor head assembly 120, such that when the sensor cartridge 122 isloaded through the distal end 134 into the internal channel 136, thesensor head assembly 120 may also limit angular movement of the sensorcartridge 122 relative to the longitudinal axis 126. In other words, thediameter of the distal end 134 and the diameter of the sensor cartridge122 are such that when the sensor cartridge 122 is inserted in theinternal channel 136, the sensor cartridge 122 is partially limited totravel linearly along the longitudinal axis 126 and rotate about thelongitudinal axis 126 (e.g., transverse rotation about the longitudinalaxis 126 is substantially eliminated).

FIG. 9 is a cut-away perspective view of the second key component 60abutted with the sensor HAC 156. As shown in the illustration, thesensor cartridge 122 is received in the internal channel 136 and isaligned along the longitudinal axis 126. However, the second keycomponent 160 and the first key component 162 are not alignedcircumferentially. Thus, the contact members 164 and 166 do not engageone another. In other words, the second contact member 164 and the firstcontact member 166 are longitudinally blocked from engaging one anotheruntil the second key component 160 and the first key component 162interlock and engage one another because the first key component 162 andthe second key component 160 extend further toward the sensor HAC 156.In other words, because the key length 194 is greater than the contactlength 196, the second key component 160 limits travel of the sensorcartridge 122 along the longitudinal axis 126. As used herein,circumferentially aligned refers to a state where the angularorientation of the sensor cartridge 122 about the longitudinal axis 126in which the first key component 166 is aligned with the second keycomponent 164.

FIG. 10 is a cut-away perspective view of the sensor cartridge 122abutted and aligned with the sensor HAC 156 in the intermediatecircumferential alignment stage. As illustrated, sensor cartridge 122 iscircumferentially aligned with the sensor HAC 156. To circumferentiallyalign the sensor cartridge 122, beginning with the orientation of thesensor cartridge 122 shown in FIG. 9, the sensor cartridge 122 isrotated within the internal channel 136 until the first key component162 aligns with the second key component 160. When circumferentiallyaligned, the first contact member 166 is aligned with the second contactmember 164.

In the final loaded stage, the first key component 162 and the secondcomponent 160 are aligned and engaged with one another, which allows thefirst key element 192 to engage the second contact member 164 to form anelectrical connection. To arrive at the final loaded stage, beginningwith the orientation of the sensor cartridge 122 shown in FIG. 10, thesensor cartridge 122 may move along the longitudinal axis 126 until thekey components 160 and 162 as well as the contact members 164 and 166are engaged and interlock. After the final loaded stage, the retainingcap 124 may be used to secure the sensor cartridge 122 to sensor headassembly 120 as described in the discussion of FIG. 4 above.

By practicing one or more of the embodiments described herein, a sensorcartridge 122 may be quickly and safely attached and detached from asensor head assembly 120.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the subject matterdescribed herein without departing from its scope. While the dimensionsand types of materials described herein are intended to define theparameters of the subject matter described herein, they are by no meanslimiting and are exemplary embodiments. Many other embodiments will beapparent to those of skill in the art upon reviewing the abovedescription. The scope of the subject matter described herein should,therefore, be determined with reference to the appended claims, alongwith the full scope of equivalents to which such claims are entitled. Inthe appended claims, the terms “including” and “in which” are used asthe plain-English equivalents of the respective terms “comprising” and“wherein.” Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112, sixth paragraph, unless and until such claimlimitations expressly use the phrase “means for” followed by a statementof function void of further structure.

This written description uses examples to disclose the subject matterdescribed herein, including the best mode, and also to enable any personskilled in the art to practice the embodiments of the subject matterdescribed herein, including making and using any devices or systems andperforming any incorporated methods. The patentable scope of the subjectmatter described herein is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal languages of the claims.

What is claimed is:
 1. A connector mechanism, the connector mechanismcomprising: a sensor head assembly, the sensor head assembly comprising:a detector body with an internal channel and an open distal end, theinternal channel having a longitudinal axis; and a sensor headattachment connector (sensor HAC) located within the internal channel,the sensor HAC oriented to face the distal end, the sensor HAC recessedwithin the internal channel remote from the open distal end of thedetector body, the sensor HAC including a first electrical connectionhaving at least a first contact member, the sensor HAC including a firstkey component that is located in a fixed location relative to the firstcontact member; and a sensor cartridge, the sensor cartridge comprising:a cartridge housing that includes a probe component, the cartridgehousing configured to be at least partially inserted through the opendistal end into the internal channel of the detector body; a secondelectrical connection having at least a second contact member configuredto mate with the first contact member; and a second key component thatis located in a fixed location relative to the second contact member,the first and second key components being configured to engage oneanother before the first and second contact members engage one another,the sensor cartridge being rotatable about the longitudinal axis of theinternal channel when the sensor cartridge is within the internalchannel to align the first key component and the second key componentwith each other.
 2. The connector mechanism of claim 1, wherein thesecond key component is configured to interlock with the first keycomponent, and wherein the first and second contact members arelongitudinally blocked from engaging one another until the first andsecond key components are aligned.
 3. The connector mechanism of claim1, wherein the cartridge housing has an outer diameter that fits withinan inner diameter of the distal end of the detector body such that, whenthe sensor cartridge is loaded through the distal end into the internalchannel, the detector body limits angular movement of the sensorcartridge relative to a longitudinal axis of the internal channel. 4.The connector mechanism of claim 1, wherein the second key componentextends a key length outward from the cartridge housing, the secondcontact member extending a contact length outward from the cartridgehousing, wherein the key length is greater than the contact length. 5.The connector mechanism of claim 1, wherein the first key componentincludes a groove and the second key component includes a standoff, andwherein the groove is configured to receive the standoff to enable thefirst and second contact members to engage one another.
 6. The connectormechanism of claim 1, wherein the cartridge housing has at least onediffusion opening.
 7. The connector mechanism of claim 1, wherein thesensor cartridge includes a pre-loaded stage where the sensor cartridgeis received in the internal channel and is longitudinally aligned withthe sensor HAC.
 8. The connector mechanism of claim 1, wherein thesensor cartridge includes an intermediate circumferential alignmentstage where the sensor cartridge is received in the internal channel,the sensor cartridge is longitudinally aligned with the sensor HAC, andthe first key component and the second key component arecircumferentially aligned with each other.
 9. The connector mechanism ofclaim 1, having a final loaded and engaged stage where the first keycomponent and the second key component are aligned and engaged with eachother, and where the first contact member and the second contact memberare engaged in electrical connection with each other.
 10. The connectormechanism of claim 1, wherein the sensor head assembly comprises a thirdkey component that is located in a fixed location relative to the firstcontact member, the sensor cartridge comprising a fourth key componentthat is located in a fixed location relative to the second contactmember, the third and the fourth key components being configured toengage each other to enable the first and second contact members toengage one another.
 11. The connector mechanism of claim 1, wherein thefirst contact member includes at least one spring-loaded contact elementthat is configured to engage the second contact member.
 12. Theconnector mechanism of claim 1, wherein the second contact memberincludes a contact pin.
 13. The connector mechanism of claim 1, whereinthe first electrical connection is recessed relative to the first keycomponent.
 14. The connector mechanism of claim 1, wherein the secondelectrical connection is recessed relative to the second key component.15. A sensor assembly, the sensor assembly comprising: a mountingstructure; and a sensor configured to be mounted to the mountingstructure such that the sensor is exposed to an environment, the sensorincluding: a sensor head assembly, the sensor head assembly having: adetector body with an internal channel and an open distal end, theinternal channel having a longitudinal axis; and a sensor headattachment connector (sensor HAC) located within the channel, the sensorHAC oriented to face the distal end, the sensor HAC recessed within thechannel remote from the distal end, the sensor HAC including a firstelectrical connection having at least a first contact member, the sensorHAC including a first key component that is located in a fixed locationrelative to the first contact member; and a sensor cartridge, the sensorcartridge having: a cartridge housing that includes a probe component,the cartridge housing configured to be at least partially insertedthrough the open distal end into the internal channel of the detectorbody; a second electrical connection having at least a second contactmember configured to mate with the first contact member; and a secondkey component that is located in a fixed location relative to the secondcontact member, the first and second key components being configured toengage one another before the first and second contact members engageone another, the sensor cartridge being rotatable about the longitudinalaxis of the internal channel, when the sensor cartridge is within theinternal channel, to align the first key component and the second keycomponent with each other, the second key component being configured tointerlock with the first key component, the first and second contactmembers being longitudinally blocked from engaging one another until thefirst and second key components are aligned.
 16. The sensor assembly ofclaim 15, wherein the sensor further comprises a retaining cap that isconfigured to be mounted to the detector body to retain the sensorcartridge to the sensor head assembly.
 17. The sensor assembly of claim15, wherein the mounting structure includes an interior chamber that ishermetically sealed from the environment.
 18. The sensor assembly ofclaim 17, wherein the mounting structure further includes at least oneof a power supply component, a processing component, and a communicationcomponent within the interior chamber.